Apparatus and method for reinforcing a vinyl beam

ABSTRACT

An apparatus and method are disclosed for reinforcing a vinyl beam. The apparatus includes an elongated sleeve with walls and an insert that may be slid into the sleeve to support the walls of the sleeve. The insert may be made from multicolored thermoplastic material and may be concealed within the sleeve. Contact points extending from an exterior surface of the insert may facilitate positioning the insert in the sleeve and may support the walls of the sleeve. A method is also presented for reinforcing a vinyl beam. The method comprises forming an insert from the material of a cleansing die batch. Furthermore, the method may include forming an insert from reprocessed rejected manufactured polymer stock.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part of and claims priority to U.S. Provisional Patent Application No. 60/502,732 entitled “SYSTEM, METHOD, AND APPARATUS FOR MAKING A REINFORCED VINYL PROFILE BEAM” and filed on Sep. 12, 2003 for Paul M. Linford and Duane M. Linford which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to vinyl beams and more particularly relates to apparatus and methods for reinforcing vinyl beams.

2. Description of the Related Art

Generally, manufacturers form vinyl beams using extrusion techniques well known to those of skill in the art. These techniques, though, often waste excessive amounts of polymer stock for several reasons. One form of waste occurs during polymer processing because polymer stock is used to prime the extrusion equipment. In addition, extruded products are commonly processed from a single die batch, or batch of raw polymer pellets, in order to provide certain aesthetic properties to a product, such as uniformity in color. Polymer stock may be wasted because the exact amount of polymer required to sufficiently satisfy a product demand may not be available. For example, polymer may be sold/purchased in a set quantity that does not correspond to the amount needed to manufacture a particular product from a single die batch. As a result, manufacturers may have excessive, unused polymer stock remaining from a die batch.

A further source of waste in polymer processing occurs when a manufacturer uses the same extruder to process polymers of different colors. Waste occurs because one or more batches of polymer must pass though the extruder to eliminate the color dye of a previous batch. During this process, the color of the batch (generally white) used to purge the old color mixes with the color of the previous batch, resulting in a non-uniform color that does not match any other die batch. Typically, stock from this mixed-color, cleansing batch of polymer is discarded.

Additionally, extruded thermoplastic components may also be wasted if the polymer swells after it passes though the die. Swelling components are problematic when the components are to be used in an assembly of components. If swelling or other defects prevent the extruded parts from engaging each other properly, the extruded parts become worthless and generally are discarded. Discarded extruded parts may cost a manufacturer a significant amount of time and money.

From the foregoing discussion, it should be apparent that a need exists for an apparatus and method to reduce the amount of material waste inherently produced during polymer processing, particularly when applied to manufacturing vinyl beams. Beneficially, such an apparatus and method would effectively utilize multicolored and reprocessed thermoplastic material. The present invention provides an apparatus and methods to use excess polymer waste to reinforce a vinyl beam.

SUMMARY OF THE INVENTION

The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available techniques to manufacture vinyl beams. Accordingly, the present invention has been developed to provide an apparatus and method for using multicolored and reprocessed thermoplastic material to reinforce vinyl beams that overcome many or all of the above-discussed shortcomings in the art.

The apparatus, in one embodiment, is configured to strengthen a vinyl beam. The apparatus includes an elongated sleeve and an insert formed of substantially the same material as the sleeve. The sleeve may have walls and an opening to receive the insert, which may be slid into the sleeve to support the walls. Preferably, the insert is concealed within the sleeve. Consequently, multicolored thermoplastic material may be used to form the insert.

The apparatus is further configured, in one embodiment, to include a plurality of contact points extending from an exterior surface of the insert. The contact points facilitate positioning the insert in the sleeve. Furthermore, the contact points may engage the walls of the sleeve to help secure the insert. In one embodiment, the exterior surface of the insert may further include a textured surface. The textured surface increases the surface area of the insert to facilitate securing the insert with an adhesive.

A method of the present invention is also presented for reinforcing a vinyl beam. The method in the disclosed embodiments substantially includes the steps necessary to carry out the functions presented above with respect to the operation of the described apparatus. In one embodiment, the method includes forming an elongated sleeve from a first die batch having a uniform first color. Then a cleansing die batch is initiated using a second color. The insert is formed from the material of the cleansing die batch passing through thermoplastic component manufacturing equipment. The method also may include inserting the insert into the elongated sleeve. Using the non-uniform, discolored, extruded material of the cleansing die batch to form a concealable insert allows a manufacturer to essentially eliminate the waste traditionally associated with changing the colors of extruded thermoplastic material.

In a further embodiment, the method for reinforcing a vinyl beam includes reprocessing rejected manufactured polymer stock into a multicolored die batch. This may include grinding rejected vinyl products or multicolored cleansing batches. Then the multicolored die batch may be used to form an insert that may be concealable within an elongated sleeve. As a result, undesired extruded material, such as multicolored stock or deformed thermoplastic components, may be used to form a useful insert.

Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.

Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.

These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

FIG. 1A is an end view illustrating one embodiment of an insert according to the present invention;

FIG. 1B is an end view illustrating one embodiment of a reinforced vinyl beam including an insert;

FIG. 2 is an end view illustrating an alternative embodiment of a reinforced vinyl beam with an insert;

FIG. 3A is a perspective view of one embodiment of a reinforced vinyl beam with holes;

FIG. 3B is a front view of a fence assembly comprising an embodiment of a reinforced vinyl beam of the present invention;

FIG. 4 is a flow chart illustrating a method for reinforcing a vinyl beam using multicolored thermoplastic material according to one embodiment of the present invention; and

FIG. 5 is a flow chart illustrating a method for reinforcing a vinyl beam using rejected manufactured polymer stock according to an alternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

FIGS. 1A and 1B illustrate selected embodiments of an insert 100 and a reinforced vinyl beam 110. The insert 100 may include contact points 102, an exterior surface 104, and a textured surface 108. The reinforced vinyl beam 110 of FIG. 1B may include an insert 100, a sleeve 106, an opening 111, a hollow section 112, and walls 114. The insert 100 is preferably configured to fit concealed within a hollow sleeve 106.

In the depicted embodiment, the insert 100 has the shape of a capital “I”, commonly known as an I-beam. Alternatively, the insert 100 may have various cross-sectional shapes including “X”, “O”, “C”, or any other cross-sectional shape. A cross-section of the insert 100 may correspond to the general shape of the interior of the sleeve 106. Alternatively, the cross-section of the insert 100 may circumscribe the interior of the sleeve 106. The insert 100 supports the walls 114 of the sleeve 106.

In the depicted embodiment, the insert 100 comprises contact points 102. The contact points 102, which extend from the insert's exterior surface 104, may contact the sleeve 106 when the insert 100 is within the sleeve 106. In certain embodiments, the contact points 102 facilitate inserting the insert 100 into the sleeve 106. Because the contact points 102 extend beyond the exterior surface 104 of the insert 100, direct contact between the insert 100 and the walls 114 of the sleeve 106 is minimized, reducing friction associated with sliding the insert 100 along the interior of the sleeve 106. In one embodiment, the contact surface area of the insert 100 is less than half of the internal surface area of the sleeve 106. In a further embodiment, the contact surface area of the insert 100 is less than a quarter of the internal surface area of the sleeve 106. Inserting the insert 100 into the sleeve facilitates concealing the insert 100.

The contact points 102 support the walls 114 of the sleeve 106. Preferably, the contact points 102 are designed to extend the “effective diameter” of the insert 100 to exceed the diameter of the sleeve 106. Consequently, the contact points 102 press against the sleeve 106 to form a tight friction-fit when the insert 100 is installed. To secure the insert 100, an adhesive may be applied to the insert 100 in the space between the walls 114 of the sleeve 106 and the exterior surface 108 of the insert 100.

In one embodiment, the raised contact points 102 run continuously along the length of the insert 100. Alternatively, the contact points 102 may extend for a specific distance or extend intermittently along the surface 104. In addition, while a pair of contact points 102 are illustrated, those of skill in the art recognize that the insert 100 may include a plurality of contact points 102 organized in various configurations. In alternative embodiments, the insert 100 may not include contact points 102.

In the depicted embodiment, the insert 100 additionally includes a textured surface 108. The textured surface 108 increases the surface area available for bonding the insert 100 to an adhesive. Alternatively, the insert's exterior surface 104 may be smooth or may be a combination of both textured and smooth. Preferably, the textured surface 108 is formed when the insert 100 is formed.

The insert 100 may selectively extend the length of the sleeve 106 to support the hollow sleeve 106 only in areas of potentially high lateral stress. Alternatively, the insert 100 may extend the entire length of the sleeve 106. The number and size of inserts 100 within a hollow sleeve 106 may vary according to the structural design of a particular reinforced vinyl beam 110.

Referring now to FIG. 1B, the insert 100 is inserted in an opening 111 of a sleeve 106. The sleeve 106 may be made from thermoplastic material and may be elongated, forming a beam. In one embodiment, the sleeve is unicolored for aesthetic purposes. The walls 114 of the sleeve 106 create a hollow section 112. The insert 100 may be positioned within the hollow section 112. Preferably, the inserts 100 create a snug fit between the insert 100 and the walls 114 of the sleeve 106. The sleeve 106 of the depicted embodiment has a substantially square cross-section. Those of skill in the art will recognize, however, that the insert 100 and sleeve 106 may comprise a variety of shapes, sizes, and material properties.

As mentioned above, the raised contact points 102 may be sized to extend slightly beyond the interior diameter of the sleeve 106. In this manner, the contact points 102, wedged between the I-beam insert 100 and the sleeve 106, bias the I-beam insert 100 against the walls 114.

In one embodiment, the insert 100 is formed by extrusion, and the sleeve 106 is formed by blow molding. Any suitable method, however, may be used to form the sleeve 106 or the insert 100. In certain embodiments, the sleeve 106 may be made of a variety of materials suitable for concealing an insert 100, including aluminum, fiberglass, wood, and the like. Preferably, the insert 100 is made from multicolored and reprocessed thermoplastic material, which we be discussed in greater detail with relation to FIGS. 4-5.

FIG. 2 illustrates an alternative embodiment of a reinforced vinyl beam 200 in which the insert 202 and the sleeve 204 are cylindrical. Accordingly, the insert 202 has a slightly smaller diameter than the sleeve 204, such that the insert 202 circumscribes the sleeve 204. To provide a snug fit between the insert 202 and the sleeve 204, the insert 202 includes two raised contact points 206. As depicted, a gap 208 may be provided between the exterior surface 210 of the insert 202 and the wall 212 of the sleeve 204. This gap 208 allows for relaxed tolerances when manufacturing the reinforced vinyl beam 200 and may be filled with an adhesive to bind the insert 202 to the sleeve 204. As described above, the exterior surface 210 of the insert 202 and the inner surface 213 of the wall 112 of the sleeve 204 may be textured to increase the surface area available for bonding.

FIG. 3A illustrates one embodiment of a reinforced vinyl beam 110 having at least one insert 100 sized to support an elongated sleeve 106. To provide greater support, the sectioned inserts 100 may be positioned within the sleeve 106 near areas of weak structural integrity. For example, the insert 100 in the illustrated embodiment is positioned section 112 provides a space in which the hole 300 may receive a beam member, such as a vinyl fence slat (not shown), a fence rail (not shown), or the like. The insert 100, consequently, may serve as a stop for a beam member inserted into the hole 300. In alternative embodiments, the insert 100 may further be configured to engage the beam member.

As depicted, holes 300 maybe positioned on a side of the sleeve 106 adjacent to the side contacting the insert 100. The I-shaped insert 100 allows the sleeve 106 to be cut easily without damaging the insert 100. In this example, although the holes 300 may weaken the sleeve 106 structurally, the insert 100 compensates for the loss in structural integrity and reinforces the sleeve 106 near the hole 300.

Because the insert 100 is hidden from view, the present invention increases the range of color diversity possible for the inserts 100 without affecting the aesthetic quality of the sleeve 106. The increased compatibility of different colors also allows manufactures to use recycled materials or materials from different die batches to form the insert 100, thus reducing the cost and waste that generally results from the polymer processing.

FIG. 3B illustrates a fence assembly 310 having an upright post 312 anchored into the ground 314. The cross-members 316 engage the upright post 312. A number of slats (not shown) may be joined to the cross members 316 to improve the privacy function of the fence assembly 310. Preferably, the reinforced vinyl beam 110 illustrated in FIG. 3A is implemented in the upright posts 312 and/or cross-members 316. In addition, the concealed insert 310 may engage and support the cross-members 316.

Typically, the elongated sleeves 106 of the fence assembly 310 are a uniform color. The inserts 100, which are not visible, may be either a uniform color or mixed. Preferably, the inserts 100 are made from remainder die batches and/or waste vinyl components of various colors that are ground up and recycled. In this manner, multicolored inserts 100 ma be provided while still providing an aesthetically appealing fence assembly 310. Furthermore, using concealed inserts 100 allows manufacturers to utilize thermoplastic material aesthetically unsuitable for exterior use, but still structurally sound and suitable for support purposes.

The schematic flow chart diagrams that follow are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

FIG. 4 illustrates a flow chart of a method 400 for reinforcing a vinyl beam 110. The method 400 utilizes multicolored thermoplastic material to form the insert 100 of a reinforced vinyl beam 110. First, an elongated sleeve 106 is formed 402. The elongated sleeve 106 may be formed 402 by extrusion or blow molding techniques from a common die batch having a consistent first color, or by any other appropriate method. Next, a cleansing die batch having a second color, such as white, for example, is initiated 404, as is known in the art. Then, an insert 100 is formed 406 from material of the cleansing die batch. The insert may be formed from multicolored or a uniform colored thermoplastic material.

Of course, complete die batches of one or more colors, or a combination of remainder die batches, may be used to form one or more inserts 100. However, because the inserts 100 are concealed, cleansing die batches are preferably used to limit the amount of vinyl material wasted during polymer processing. The insert 100 is then installed 406 into the sleeve 106 to form a reinforced vinyl beam 110. In certain embodiments, the insert 100 is bonded to the wall 114 of the sleeve 106 by an adhesive. As mentioned, the sleeve 106, which conceals the insert 100, preferably has a uniform color and an aesthetically pleasing appearance.

FIG. 5 illustrates a flow chart of a method 500 for reinforcing vinyl beams 110 from recycled materials. First, an elongated hollow sleeve 106 is formed 502 as mentioned above. Next, rejected manufactured polymer stock is reprocessed 504 into a multicolored die batch or uniform die batch. In one embodiment, the rejected thermoplastic material is ground into a die batch. Then, the die batch of recycled materials may be used to form 506 a concealable insert 100. In one embodiment, a multicolored die batch is extruded to form 506 an insert 100. Finally, the insert 100 may be installed 508 into a hollow sleeve 106. An insert 100 may also be formed from other suitable types of recycled material. The method 500 reduces the amount of thermoplastic material wasted during polymer processing by recycling unwanted materials and creating a desirable product.

The method 400 and method 500 may further include forming contact points 102 and a textured surface 108 on the exterior surface 104 of the insert 100. The insert 100 may then be inserted into a sleeve 106 to form a reinforced vinyl beam 110.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1. An apparatus for reinforcing a vinyl beam, the apparatus comprising: an elongated sleeve having walls and an opening configured to receive an insert; and the insert formed of substantially the same material as the sleeve and configured to be slideably inserted into the sleeve to support the walls of the sleeve, the insert being concealable within the sleeve.
 2. The apparatus of claim 1, wherein the insert further comprises a plurality of contact points extending from an exterior surface of the insert and configured to support the walls of the sleeve.
 3. The apparatus of claim 2, wherein the plurality of contact points has a contact surface area less than half of the internal surface area of the sleeve.
 4. The apparatus of claim 2, wherein the plurality of contact points has a contact surface area less than a quarter of the internal surface area of the sleeve.
 5. The apparatus of claim 2, wherein the contact points together with the insert have a cross-sectional diameter greater than an interior cross-sectional diameter of the sleeve.
 6. The apparatus of claim 1, wherein the exterior surface of the insert comprises a textured surface.
 7. The apparatus of claim 1, wherein the sleeve is formed of a unicolored thermoplastic material.
 8. The apparatus of claim 1, wherein the insert is formed of a multicolored thermoplastic material.
 9. The apparatus of claim 8, wherein the multicolored thermoplastic material is recycled from waste vinyl material.
 10. The apparatus of claim 1, wherein the insert is configured to engage a beam member.
 11. A method for reinforcing a vinyl beam, the method comprising: forming an elongated sleeve from a first die batch having a uniform first color, the elongated sleeve having walls and an opening configured to receive an insert; initiating a cleansing die batch having a second color; and forming an insert from material of the cleansing die batch passing through thermoplastic component manufacturing equipment, the insert configured to be slideably inserted into the sleeve to support the walls of the sleeve, the insert being concealable within the sleeve.
 12. The method of claim 11, further comprising inserting the insert into the elongated sleeve.
 13. The method of claim 11, further comprising forming a plurality of contact points extending from an exterior surface of the insert and configured to support the walls of the sleeve.
 14. The method of claim 13, wherein the method comprises forming a plurality of contact points having a contact surface area less than half of the internal surface area of the sleeve.
 15. The method of claim 13, wherein the method comprises forming a plurality of contact points having a contact surface area less than a quarter of the internal surface area of the sleeve.
 16. The method of claim 11, further comprising forming the sleeve by blow molding.
 17. The method of claim 11, further comprising forming the insert by extrusion.
 18. The method of claim 11, further comprising forming a textured surface on the exterior surface of the insert.
 19. A method for reinforcing a vinyl beam, the method comprising: reprocessing rejected manufactured polymer stock into a multicolored die batch; and forming an insert from the multicolored die batch, the insert configured to be slideably inserted into an elongated sleeve to support the walls of the sleeve, the insert being concealable within the elongated sleeve, the elongated sleeve having walls and an opening configured to receive the insert.
 20. The method of claim 11, further comprising forming a plurality of contact points extending from an exterior surface of the insert and configured to support the wails of the sleeve. 